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SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Bulletin AE01B-A0587-001 © 2011 - 2012 CommScope, Inc. All rights reserved Rev: C (1/12) SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Section 1 Tabel of Contents General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.3 Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.4Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Figure 1 — Discrete Alarm Terminal Strip with Summary Alam . . . . . . . . . . . . . . . . . .5 Figure 2 — Summary Alarm Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Figure 3 — Pin and Jumpers Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.5 Specifications SAHARA Series Dehydrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Section 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1 2.2 2.2.1 2.3 2.3.1 2.4 2.4.2 2.5 2.4.1 2.6 2.6.2 2.6.3 2.6.4 2.7 2.6.1 2.8 Section 3 Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Controls and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Event Log Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Installing the Dehydrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Set on bench or the floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Test the Dehydrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connecting the Alarm Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Connecting Dehydrator to the Transmission Line . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Figure 4 — SAHARA Series System configuration diagram Basic . . . . . . . . . . . . . . . 9 SAHARA Series System configuration diagram Multi-Line . . . . . . . . . . . . . . . . . . . . .9 Figure 5 — SAHARA Series System configuration diagram Multi-Line . . . . . . . . . . . . 9 Pressure Monitoring and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Dehydrator Duty Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Purging the Transmission Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 SAHARA Series System configuration diagram Basic . . . . . . . . . . . . . . . . . . . . . . . 9 PC Interface to B-Version Dehydrator Control Board . . . . . . . . . . . . . . . . . . . . . . . 10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.2 Dehydrator Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.2.1 Replace the coalescing filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.3 Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.3.1 Check the electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.3.2 Check the ground wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.3.3 Check the hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.4 Parts Replacement and Dehydrator Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.4.1 In Case Of Difficulty: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.4.2Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.4.3 Overhaul Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.4.4 Unit Shutdown and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.4.5 Unplug the unit from the power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.5 Service Restoration RECOMMENDATION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 6 — Electrical Diagram SAHARA2 and SAHARA2A . . . . . . . . . . . . . . . . . . . 17 Figure 7 — Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Section 5 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Section 6 Overhaul Kit SAHARA-KIT-OVRHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Filter Element Replacement Kit SAHARA-KIT-ELMNT . . . . . . . . . . . . . . . . . . . . . . 19 Filter Bowl Assemble Replacement Kit SAHARA-KIT-FLTRS . . . . . . . . . . . . . . . . . . 19 Dryer Tube Replacement Kit SAHARA-KIT-DRYER . . . . . . . . . . . . . . . . . . . . . . . . 19 Solenoid Replacement Kit SAHARA-KIT-SOLND . . . . . . . . . . . . . . . . . . . . . . . . . 19 Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 6.0Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 6.1 In Case of Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 6.2 Initial Steps by CommScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 6.3 Repair Center Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 6.4 RoHS Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Section 1 General Information 1.1 The SAHARA Series maintains transmission line pressures from 14-34 kPa (2.0 to 5.0 psig). It is intended for standard microwave antenna/Broadcast applications and any other transmission line pressurization requirement that supports a medium pressure limit. Introduction This manual contains the information you need to install, operate and maintain your SAHARA Series DryLine® Dehydrator. Please take the time to read this manual before attempting to operate or service the unit. 1.3 Theory of operation The SAHARA series of DryLine® Dehydrators, while similar in moisture removal technology, operates differently than some of the DryLine® series of dehydrators. In order to maintain a positive constant level of pressure to medium air volume systems, and to maintain an acceptable dryness level in the product air stream, a downstream pressure sensor is utilized for controlling the operation of the unit. This feedback controlled sensor prompts the unit to engage at 14 kPa (2.0 psig) and shut down at 34 kPa (5.0 psig). In addition to monitoring the downstream flow, the system is also set up to utilize the downstream air volume to provide the dry air for the feedback loop. The feedback loop is necessary to maintain the dryness of the membrane cartridge and will consume a small percentage of the air supplied by the dehydrator. CAUTION: This appliance is not intended for access by the general public. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. During normal operation, the bleed air in the feedback loop will cause the pressure to slowly drop in the downstream air volume, and the SAHARA compressor will cycle automatically. The dehydrator will only cycle off when it sees a down stream pressure of 34 kPa (5.0 psig). The rate of these cycles, however, will vary based on system volume and overall system leak rate. 1.2Description When connected to a normal system, the dehydrator’s duty cycle should not exceed 10% and will maintain the system pressure between 14 kPa (2.0 psig) and 34 kPa (5.0 psig). If the duty cycle significantly exceeds 10%, check the system for leaks. When open to atmosphere, the dehydrator will run continuously and provide approximately 56.3 SLPM (2.0 SCFM). SAHARA Series dehydrators provide dry air for pressurizing large (2830 to 31,150 liters (100 and 1100 ft3), antenna and transmission line systems. The dehydrators produce -45ºC (-50ºF) dew point dry air at a nominal volumetric flow rate of 56.3 SLPM (2.0 SCFM). Each dehydrator consists of an electrically driven air compressor, a membrane dryer assembly, an automatic transmission line pressure sensing system, and alarm outputs housed in a rigid metal chassis. It is designed as a free-standing unit. The front panel features a control interface with display for alarms and pressure. For easy serviceability, power connections, alarm output connections, and all filter elements are accessible from the outside. The display will also reflect a pressure between 0 and 34 kPa (5.0 psig) while the output flow is between 0 and 56.3 SLPM (2.0 SCPM). The pressure sensor measures pressure at the Remote Sense port and will show the actual pressure in the transmission lines (or to the distribution manifold). 4 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL 1 1.4Alarms The SAHARA Series offers Low Pressure and Excess Run alarms as a standard feature. In addition, a summary alarm connection is provided on all units. Additional alarms are available in the discrete alarm version. These include High Humidity and Power Fail alarms. All four alarms, plus the summary alarm, have discrete connection contacts. Alarm conditions are indicated on the display. The alarms are Form C dry contacts and have connection options for Normally Open (NO) or Normally Closed (NC) configurations. WIRE FUNCTION REFERNCE The external alarm monitoring system (supplied by others) is connected to the terminal strip located on the rear of the cabinet. A small slotted screwdriver is necessary to make the connections. WIRE TERMINAL COLOR 3 BLACK SUMMARY NC 2 WHITE SUMMARY COM 1 RED Summary: Activates when Excess Run, and/or Low Pressure alarms are triggered. It will also report High Humidity if unit is equipped with full alarms. The summary alarm does not report Power Fail. Power Fail: Activates when power is removed from the dehydrator. This includes turning the power off at the switch. High Humidity: Activates when system or dehydrator output humidity rise above 7.5% relative humidity. At initial installation, this alarm will continue to alarm until the system has been properly purged. Excess Run: Factory strapped run time set in accordance with the normal run time for the dehydrator application. Selectable times are 1, 10, 30, 120 and 240 minutes, with the 10 minute selection used on the SAHARA Series as the default setting. Low Pressure: If system pressure falls below the low-pressure trigger point (7 kPa (1.0 psig) on the SAHARA Series), the low-pressure alarm sensor will activate an alarm contact. This alarm is an indication of a significant system leak or a dehydrator failure. 1 Summary 1Discrete Figure 1 — Discrete Alarm Terminal Strip with Summary Alam DISCRETE WIRE FUNCTION REFERNCE COLOR ALARM FUNCTION 1 WHITE 2 TAN 3 BLUE 4 BROWN 5 PINK 6 GREEN HIGH HUMIDITY NC 7 BLACK POWER FAIL NO 8 VIOLET POWER FAIL COM EXCESS RUN NO EXCESS RUN COM EXCESS RUN NC HIGH HUMIDITY NO HIGH HUMIDITY COM 9 RED 10 ORANGE LOW PRESSURE NO 11 YELLOW LOW PRESSURE COM 12 GRAY SUMMARY NO Figure 2 — Summary Alarm Terminal Strip Alarm Definitions: The connections to the alarm strip are as follows; refer to Figure 1 for correct locations and colors of the wires on the terminal strip. WIRE TERMINAL ALARM FUNCTION POWER FAIL NC LOW PRESSURE NC 5 Note: All of the alarms clear and reset automatically, but can be manually reset in the display menus. However, if the alarm condition still exists, the alarm will return immediately after being reset. SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL NOT IN USE USB P1 HIGH PRESSURE SENSOR U2 Vdc INPUT P2 (MR050B ONLY) HUMIDITY SENSOR P3 COMP OUTPUT P4 LOW PRESSURE SENSOR U4 SOLENOID (FILTER DRAIN) P6 [ [ AC MAIN 48 Vac COMP OUTPUT P7 (MR050B ONLY) 1.5 SUM ALARM P8 KEYPAD J4 (NO/NC) DISCRETE ALARMS P9 (NO/NC) Figure 3 — Pin and Jumpers Location Specifications SAHARA Series Dehydrator Output Pressure, kPa (psig) 14-35 (2.0-5.0) Output capacity 56.6 SLPM (2.0 SCFM) (total, approx.) Output Dew Point, -45° C (-50° F) or better Operating Temperature Range Electrical Input SAHARA2 & SAHARA2a SAHARA2 & SAHARA2a Output Connector Dimensions Height, mm (in) w/feet without feet Width, mm (in) Depth, mm (in) Net weight, kg (lb) 292 (11.5) 267 (10.5) 432 (17.0) 381 (15.0) 24.95 (55.0) Alarms -10° to 40° C (14° to +104° F) Power Fail Alarm (optional) High Humidity Alarm Set Point (optional) 220 Vac, 60 Hz 240 Vac, 50 Hz Excess Run Alarm 3/8” polytube, compression Low Pressure Alarm, kPa (psig) 6 loss of input power 7.5% RH, factory set 10 minutes, factory set 6.9 (1.0) SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Keypad Controls: Section 2 Installation 2.1 Advances display (scrolls ahead) to the next display or program mode with out changing the values in the microprocessor memory. Unpacking and Inspection Open carton. Enters into the microprocessor memory the values displayed in the window and advances display (scrolls ahead) to the next program or display mode. Numerically increase displayed settings in display window. When depressed longer than 1/2 second scrolling will occur at a faster rate. Numerically decrease displayed settings in display window. When depressed longer than 1/2 second scrolling will occur at a faster rate. Remove the top piece of foam packaging. Carefully remove the installation accessories and manual and dehydrator. Check the dehydrator for shipping damage such as dents or loose parts. 2.2 Used to allow the user quick access to the system event log. 2.2.1 Controls and Displays Default password is 1111 Event Log Codes EV= 0 Event = Power Up Familiarize yourself with the controls and displays prior to installing or testing the dehydrator. EV= 1 Event = High Humidity Alarm EV= 2 Event = Excessive Run Time Alarm EV= 3 Event = Low Pressure Alarm EV= 4 Event = High Pressure Alarm EV= 5 Event = Compressor Fault EV= 6 Event = Log Cleared EV= 7 Event = Powering Down EV= 8 Event = Compressor Lifetime Eeprom Fail 2.3 Installing the Dehydrator 2.3.1 Set on bench or the floor 2.4 Power Connections Confirm your dehydrator electrical input matches the available power. 7 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Ensure an electrical safety ground is installed on the ground stud located adjacent to the power input connector. (It is intended to be customer installed in the field to your halo grounding system.) 1Summary 1 Discrete SAHARA2 & SAHARA2A 220 Vac, +/- 10% 60 Hz 240 Vac, +/- 10% 50 Hz 2.4.1 Place alarm connection wires in proper terminals and tighten the screw on the terminal block. AC Power AC units should be connected into a standard 30 amp power receptacle of the proper voltage. Make sure the power circuit is properly grounded. (See section 4) The relay contacts are rated at 2 A (noninductive), 30 Vdc. Ground Stud 2.6 Connecting Dehydrator to the Transmission Line CAUTION: Check the antenna and transmission line system pressure rating before connecting the dehydrator to the system. Insert one end of the 3/8” poly tube feed line tubing into the fitting on the dehydrator output port. Connect the other end of the poly tube to the transmission line. CAUTION: Proper electrical connection is required. It is suggested a licensed electrician be contracted to connect the AC wiring to the unit, if it is connected directly to the mains. Failure to properly connect the power wires could result in a dangerous electrical shock hazard. Connect the Remote Sense Line Tubing. Insert a single tubing run from the transmission line into the fitting on the rear of the unit marked “Remote Sense”. Install the isolation shutoff valves. The valves when used on output lines, allow the system to retain pressure while the system is removed for servicing. Place each valve in line between each output and transmission line. CAUTION: This unit is designed for connection to a single phase power source. Connection to a 3 phase power source will cause significant damage to internal components. 2.4.2 Install the Output line and the Remote Sense line in separate ports on the gas inlet. If a second port is not available, install a tee in the gas inlet at the transmission line and connect both the outlet and Remote Sense to the tee. However, this type of connection could cause excessive back pressure in the dehydrator, causing it to short - cycle. Test the Dehydrator Turn the dehydrator ON and check the output port on the rear of the unit after five seconds of operation to make sure air is flowing. 2.5 Connecting the Alarm Outputs To connect the alarms, locate the terminal block (TB-1) on the rear of the unit. 8 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL *CAUTION: * Do not operate the unit with the Remote Sense line disconnected, this may result in an over pressure condition. Also be sure that any isolation valves are open before operating the unit. 2.6.1 * SAHARA Dehydrator This configuration shows proper hook up for systems when only a single waveguide is required in the system. Remote Pressure Sense Line * Any other Monitor or Manifold can be used in this location to expand the system. Isolation Shut-off Valves Tee Fitting DP-4A-001 or 6600D or L6600D or LM400 Series Manifold Primary Large Wave Guide Outputs to other Wave Guides Isolation Shut-off Valves Figure 5 — SAHARA Series System configuration diagram Multi-Line Dehydrator Output Line 2.6.3 SAHARA Dehydrator Pressure Monitoring and Control Pressure Monitoring Points Dehydrator output pressure is monitored at the transmission line on all models by the “Remote Sense” port on the rear of the unit. Figure 4 — SAHARA Series System configuration diagram Basic 2.6.2 Primary Large Wave Guide Dehydrator Output Line SAHARA Series System configuration diagram Basic * Remote Pressure Sense Line 2.6.4 SAHARA Series System configuration diagram Multi-Line Dehydrator Duty Cycles The dehydrator is programmed at the factory to start when the output pressure of the dehydrator drops to 13.8 kPa (2 psig) and stops when the pressure reaches 34.5 kPa (5 psig). This configuration shows proper hook up for systems when more than a single wave waveguide is required in the system. For larger systems, a 6- output manifold can be added. This diagram can also be used for hooking a DP-4A-001 or 6600D Series or LM400 Series Manifold to the system. Some system components, however, have lower pressure ratings. If this is the case please contact CommScope Customer service. Note: If the transmission lines have not been purged, continue with section 2.7. Otherwise proceed to section 3. 2.7 Purging the Transmission Line Air in the transmission line system must be replaced with dry air to ensure satisfactory operation of the transmitted signal. 1. Determine the total system volume. 9 2. Divide the system volume by the flow rate of the dehydrator 3398 SLPH (120 SCFH) to determine the number of hours needed for one purge cycle. SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL new time that the unit is connected. 3. Open the far end of the transmission line. 5. Choose the virtual com port from the dropdown list. It should be Com3 or Com4 for the first time that you load firmware; click “Next”. 4. Operate the dehydrator for no less than three purge cycles. If it is not possible to open the far end of the transmission line, follow these steps: 6. In the Port Settings screen, change the “Bits per Second” setting to 19200 and change the “Flow Control” setting to None. 1. Connect the dehydrator to the transmission line and pressurize the system. The system pressure should reach 34 kPa (5.0 psig). 7. Turn Caps Lock on. Type “ID” into the blank field and hit enter. The program should respond with a list of data including serial number, hardware and firmware version, etc. 2. Wait 15 minutes while the air absorbs moisture in the system, then disconnect the dehydrator from the transmission line and allow the air to vent. If it does not respond with this, your connection did not work. The virtual com port selection is generally the issue here. Start a new connection and try again. 3. Repeat steps 1 and 2 twelve times to purge the system. 2.8 8. Once successfully connected, you can enter “HELP” to view a list of commands. PC Interface to B-Version Dehydrator Control Board 9. In order to access your unit’s entire event log, click on Transfer on the command bar at the top of the page. Click on “Capture Text” in the drop-down menu and then choose a location on your computer to store the text file. Type in “GLOG” and hit enter. Click on Transfer again and click on Transfer Text and select Stop from the side-scroll menu. 1. Turn off dehydrator remove top cover; connect a USB 2.0 and mini-USB cord between the computer and the dehydrator control board. The mini-USB connector is found on the upper left corner of the controller board and is marked "USB". (See image below). 10. Open the text file from the storage location. Copy the entire text to MS Word to view the event log correctly. 11. When viewing events on the display of the unit, the following codes will be shown. 2. Once the unit is powered up and connected to the computer, a Found New Hardware Wizard may open. Select “No, not this time” and click “Cancel”. 3. Go to the Start menu > select Programs > Accessories > Communications > HyperTerminal. 4. The HyperTerminal will ask for a Connection Description Name. This is not relevant for this device, so type anything into this field; it will not be useful once the board is disconnected from the computer. A new connection will need to be established every 10 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL LCD “EV= 0” “EV= 1” “EV= 2” “EV= 3” “EV= 4” “EV= 5” “EV= 6” “EV= 7” “EV= 8” - - - - - - - - - Reference in code LOGEV_POWERUP LOGEV_HH_ALM LOGEV_XR_ALM LOGEV_LP_ALM LOGEV_HP_ALM LOGEV_CP_ALM LOGEV_CLR LOGEV_PWRDWN LOGEV_CL_FAIL – – – – – – – – – Log download string “Event = powering up” “Event = humidity alarm trip" “Event = excessive run time alarm trip" “Event = low-pressure alarm trip" “Event = high-pressure alarm trip" “Event = compressor fault trip" “Event = log cleared" “Event = powering down” “Event = Comp lifetime eeprom fail" 12. For each additional unit that is re-flashed, the virtual Com port will increment by one. If the first unit is Com3, the next will be Com4 and so on 11 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Section 3 Maintenance 3.0Maintenance The SAHARA Series Dehydrator requires relatively little maintenance to ensure satisfactory operation over long periods of time. This section outlines the recommended annual preventive maintenance for the unit and the suggested overhaul for every 6000 hours of compressor operation. 3.1 Preventive Maintenance The annual maintenance of a SAHARA Series consists of a preventative maintenance inspection of the dehydrator and replacement of the felt air intake filter if necessary. These tasks can easily be performed in the field with the unit connected to the transmission line system and with only the front and top corner opened for maintenance. In addition to the annual inspection, a complete overhaul is recommended every 6000 hours or sooner if local conditions warrant. CAUTION: Do not apply oil or other chemicals to the filter element. Make sure the element is seated completely in the housing and then replace the cover. Discard old elements. 3.3 Annual Inspection Warning: Electrical Hazard! Unplug power cord before servicing unit. Inspection includes checking for loose or damaged hoses, fittings and electrical connections. Open the top cover and front door and verify that there is no significant water buildup in the two filter bowls located inside the front cover of the dehydrator. There may be some droplets of water in the filter bowls (the lower portion of each bowl), but there should be only a small amount of liquid in either bowl. 3.2 Dehydrator Filter Element Replacement 3.2.1 Replace the coalescing filters Remove front cover, turn filter bowl housing CCW, to remove coalescing filters element. No need to remove any hoses. From the front of the dehydrator, the left coalescing filter is 5.0 micron and the right coalescing filter is 0.01microns. The coalescing elements should be replaced every 6000 hours of operation. To replace filter coalescing elements due things in reverse orders. 12 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL 3.4 If there is excessive water, refer to the troubleshooting section 4. Replacement of the elements in the coalescing filters is covered in the maintenance section of this manual. 3.3.1 CommScope SAHARA Series DryLine® Dehydrator are designed to give many years of trouble-free service and require very minimal maintenance. The dehydrator contains, as a standard feature, an hour meter that records compressor run hours. To ensure continuous and reliable operation, the dehydrator must be overhauled every 6000 hours of compressor operation. The kits, shown in Section 5, contain all of the necessary parts to perform this overhaul. The dehydrator overhaul kit includes parts to overhaul the compressor and critical components in the dehydrator that often become worn over time. Check the electrical connections. Check the screw at the power input connector to ensure that the AC power cord is securely terminated. Check the screw-in alarm terminals to ensure that all wire connections are tight. A loose or damaged connection may result in erratic operation and unnecessary downtime. Refer to the troubleshooting section 4 if an electrical problem is encountered. 3.3.2 3.3.3 Parts Replacement and Dehydrator Overhaul 3.4.1 Check the ground wire Check that an electrical safety ground is installed on the stud on the rear of the dehydrator. This connection point is adjacent to the power input connector. (It is intended to be customer installed to the halo grounding system.) In Case Of Difficulty: If the dehydrator is not operating, refer to Section 2 on Installation and Section 4 on troubleshooting the unit. 3.4.2Tools The following tools are used in the maintenance and overhaul procedures. Check the hour meter Check the hour meter on the display to determine the duty cycle of the dehydrator. If the dehydrator has been running for more than 10% of its installed time, check the systems for leaks. Also check the time on the meter to determine if it is time to perform the 6000-hour overhaul. 3.4.3 • Adjustable open-end wrench • #2 Phillips screwdrivers • Small flat-blade screw-driver Overhaul Procedure When the SAHARA compressor run time reaches 6000 hours (or a multiple of 6000 hours) it is time to replace certain items in the compressor and the air path of the dehydrator. These include the piston cups, piston seals and head gaskets of the compressor, the filter elements in the water and coalescing filters, and the tube section connecting the compressor output to the heat exchanger. In addition, if the unit gives the dryer pressure alarm, the compressor may be in need of an overhaul. This does not always coincide with the 6000 hour time frame. If the dryer pressure alarm is triggered, check the system for leaks. If no leaks are detected, the compressor will need to be overhauled. 13 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL 3.4.4 Unit Shutdown and Removal room, to purge the membrane dryer of any acquired moisture, before reconnecting to the transmission line system. In order to perform an overhaul on the SAHARA Series, the unit must be turned off and removed from service. As this is being done, the low pressure alarm may activate through a reporting alarm system. Personnel monitoring such an alarm should be notified in advance so that they are aware of the fact that service is being performed. It is also necessary to disconnect the dehydrator dry air output from the waveguide system during the overhaul. If isolation valves have been installed between dehydrator/remote pressure sense line and transmission line, close valve before removing unit service to prevent pressure loss. 3.4.5 Unplug the unit from the power supply. Follow the instructions included in the compressor overhaul kit. When the overhaul is complete, reinstall. Complete overhaul can be done without removing the compressor from the chassis. The compressor head, air filter, output port and relief valve can all be removed though top panel. When the overhaul is complete, reinstall. 3.5 Service Restoration RECOMMENDATION: If the dehydrator overhaul process has taken more than a few hours, it is recommended that the unit be run for one hour into the 14 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Section 4 Troubleshooting If you experience difficulty with your dehydrator, use the troubleshooting procedures described below. Caution:Electrical troubleshooting requires access to potentially dangerous voltages and should only be performed by a licensed electrician Problem/Condition Solution If the display light falls to light, make sure the unit is plugged in and power outlet is operating. Dehydrator display does not light, unit does not run. If you still have no light, unplug the unit, remove the unit cover and check for loose connections. Refer to the wiring diagram for proper connections. Check to ensure that proper AC voltage is being supplied to the input. (See figure 6) Turn shut-off valve to the off position and observe pressure gauge. The pressure gauge line should read approximately 34 kPa (5.0 psig) and the alarm should clear. If alarm does not clear, remove cover and verify tubing and wiring connections are secure. (See figure 6) Low-pressure alarm activated. With dehydrator isolated from transmission line, observe pressure in transmission line. If pressure drops, use a leak detector solution to locate leaks in the transmission line. Repair leaks if possible. If the problem persists contact CommScope Customer Service. (See Section 6) Check the display on the controller. Toggle the ON/OFF switch (attached to power connection). Compressor does not turn. Check input voltage per wiring diagram If the problem persists contact CommScope Customer Service. (See Section 6) Ensure that the drain line tubing (exiting the bottom of the drain solenoid) is not clogged. When the compressor cycles ON, air and moisture should flow out of the drain line (into drain pan) for a few seconds while the valve is open. Filter bowls show excessive water. If solenoid does not vent, verify proper voltage is present for the first few seconds after the compressor starts and drops to 0 volts. If proper voltage is present and solenoid does not shift, replace 15 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Left blank for notes. 16 SAHARA2A ONLY FAN 4 HUM P3 GROUND GREEN BS 5 WHITE WHITE BLACK BLACK E BLACK W H IT WHITE SUM ALARMS P8 PINK BS 1 WHITE FAN 3 WHITE BLACK WHITE SPARK FILTER SOLENOID 1 WHITE SOLENOID 2 BLACK FAN 1 17 BLACK FAN 2 EMI FILTER BS 4 BLACK BS 3 WHITE BS 8 BLACK BS 7 WHITE EMI FILTER W H B S IT 6 E 1 POWER RELAY WHITE WHITE GREEN BLACK BLACK BLACK Compressor 6 BLACK EMPTY BLACK WHITE BLACK PINK BS 2 BLACK COMPRESSOR CAPACITOR Figure 6 — Electrical Diagram SAHARA2 and SAHARA2A GROUND GREEN WITH YELLOW STRIP DISCRETE ALARMS SAHARA2A ONLY P9 POWER ENTRY MODULE SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL 18 HI PRESSURE SENSOR LINE (red) LOW PRESSURE SENSOR LINE (blue) CONTROL BOARD DRYER ASSEMBLY SOLENOID DRAIN PAN BACK PRESSURE COMPRESSOR 0.01 MICRON FILTER AIR OUTPUT POP OFF VALVE 5.0 MICRON FILTER Figure 7 — Pneumatic Diagram SOLENOID REMOTE SENSE AIR INTAKE HEAT EXCHANGER SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Section 5 Replacement Parts Section 6 Customer Service The following is a list of the replacement kits for the SAHARA Series dehydrators: 6.0Introduction CommScope provides in-warranty and outof-warranty repairs as well as dehydrator and compressor overhauls from several Repair Centers. Coordination of these services is provided through the nearest Sales Office or Customer Service Center. The Center is also prepared to help you with the following: Overhaul Kit SAHARA-KIT-OVRHL 6.1 Filter Element Replacement Kit SAHARA-KIT-ELMNT • Technical Assistance • Troubleshooting • Repairs • Loaner Units • Spare Parts • Installation Materials • System Accessories In Case of Trouble The first step you should take if trouble develops using a dehydrator is to read the operators manual and follow the trouble isolating procedures given in it. If the steps in the manual do not identify and remedy the problem, then contact an CommScope Customer Service Center for 24– hour telephone assistance. Filter Bowl Assemble Replacement Kit SAHARA-KIT-FLTRS Model Number Dryer Tube Replacement Kit SAHARA-KIT-DRYER Serial Number Record the Model Number (e.g. SAHARA) and Serial Number from the product label, as you will be asked for these when you call. Two main locations are currently available to help: From North America Telephone: 1-800-255-1479 Fax (U.S.A.): 1-800-349-5444 Solenoid Replacement Kit SAHARA-KIT-SOLND 19 SAHARA SERIES DryLine® DEHYDRATOR USER MANUAL Loaner Units: Loaner units are available from the repair center to maintain your system while repairs are being performed. If you feel you need a loaner, please contact us at at one of the numbers listed under contact numbers. A P.O. for the full value of the unit must be issued prior to shipment. Also contact us when the loaner is ready to be returned so that we can issue a NEW RMA number to identify your return and create the appropriate credit to your account. Damages to loaner will be deducted from the P.O. International Telephone: +1-779-435-6500 Fax Number: +1-779-435-8579 Web Access Internet: www.commscope.com email: #[email protected] 6.2 Initial Steps by CommScope When your call or fax communication is received, the CommScope staff will work with you to pinpoint the possible cause of trouble. If the pressurization equipment is suspect, they will: 6.3 • ask for your unit Model Number and Serial Number • check the warranty status of the unit • advise the availability of a loaner unit • provide an estimate of the cost for inspection and repairs, if the unit is out–of–warranty • fax a Return Material Authorization Sheet to you. Packing Instructions: Pack your unit securely for shipment to the Repair Center. If you received a loaner unit, we suggest you use the box and packing materials to return your unit. Otherwise we have factory packing materials available for a nominal fee. Enclose a completed copy of this form inside the box and clearly mark your Company Name and RMA: XXXXXXX on outside of the box. Address the box to the following Ship–To Address: COMMSCOPE PRESSURIZATION SERVICE CENTER RMA# XXXXXXX 11312 S. PIPELINE RD. EULESS, TX. 76040-6629 Repair Center Process A method of Payment must be provided prior to issuing of RMA regardless of warranty status. Please note, Units received with Biological/animal contamination will be returned unrepaired or scraped after notification and you will be invoiced for inspection and freight. In–Warranty Repair: Most CommScope pressurization products carry a warranty of one to three years, depending upon model number. Warranty details are available on our web page. If your unit falls within its warranty period, inspection and repairs will be performed at no charge and the unit will be promptly returned to you. If a warranty unit is deemed no problem found an inspection fee and freight will be charged to the customer. Contact Numbers: If you have any questions about the repair process or status of your unit, please contact us directly through one of the following methods – Telephone (below) TEL:817-864-4150 817-864-4155 Out–Of–Warranty Repair: We will inform you with the cost of repair and obtain your approval to proceed with repairs or, if you elect not to have the unit repaired, your instructions on disposition of your unit. When repairs are complete, we will return your unit and invoice you for the inspection charge, materials used for the repair and labor applied to complete the repair. If you elected not to repair the unit, we will invoice you for the inspection and freight charge if unit is to be returned. FAX:817-864-4179 6.4 RoHS Inquiries For inquiries on RoHS please contact the following: 20 CommScope Inc. Corke Abbey, Bray Co., Dublin, Ireland Attn: Legal Department